System for charging cordless power tool battery

Abstract

A system for charging a plurality of cordless power tool batteries includes a charging circuit and a plurality of docking stations. The charging circuit comprises: a plurality of electrical connectors connectable to up to j > 1 electrical loads; and a main control circuit to direct the DC output power to k < = j of the electrical connectors respectively and continuously connected to k < = j electrical loads. A plurality of docking stations are connectable to a plurality of electrical connectors as k < = j electrical loads. Each docking station comprises: a charging port to receive up to m > 1 of the cordless power tool batteries; and an auxiliary control circuit to direct the DC output power to respectively and continuously recharge n < = m of the cordless electric tool batteries received by the plurality of charging ports under the control of the main control circuit.

Description

Technical Field

[0001] The present disclosure relates generally to charging of rechargeable batteries, and particularly to charging cordless power tool batteries. Background Art

[0002] Property maintenance tasks are often performed using a variety of tools and / or machines that are configured to perform the corresponding specific tasks. Certain tasks, such as felling trees, trimming vegetation, blowing debris, etc., are often performed by hand-held tools or electric devices. Hand-held electric devices can often be powered by either gas or electric motors. Before the advent of battery-powered cordless power tools, operators who desired or needed a lot of mobility often preferred gas-powered motors. But as battery technology has continued to improve, the ruggedness of battery-powered devices has also improved, and such devices have become increasingly popular.

[0003] Many commercial lawn, garden and landscaping operations employ cordless power tools, and these operations require the maintenance of a large number of batteries on a daily basis. The goal is to provide a solution that can recharge their batteries overnight in a facility where alternating current (AC) power is readily available so that they are ready for the next workday. Current solutions of using separate chargers to charge a series of batteries are inconvenient and inefficient because these solutions require multiple power outlets and even require an upgrade to the traditional electrical system to provide enough wall sockets to plug in multiple chargers, often as many as 20 to 30 chargers.

[0004] Therefore, it would be desirable to have a system and method that takes into account at least some of the issues discussed above as well as other possible issues. Summary of the invention

[0005] An exemplary implementation of the present disclosure relates to charging a cordless power tool battery. Therefore, the present disclosure includes but is not limited to the following exemplary implementations.

[0006] Some exemplary implementations provide a system for charging multiple cordless power tool batteries, the system comprising: a charging circuit, including: a power circuit, configured to convert alternating current (AC) input power into direct current (DC) output power; multiple electrical connectors, capable of connecting to up to j>1 electrical loads; and a main control circuit, configured to direct the DC output power to k≤j of the multiple electrical connectors, respectively and continuously connected to k≤j electrical loads; and multiple docking stations, capable of connecting to the multiple electrical connectors via wires as k≤j electrical loads, each of the multiple docking stations comprising: an electrical connector, capable of connecting to one of the multiple electrical connectors via wires to receive DC output power from the charging circuit; multiple charging ports, configured to receive up to m>1 of a plurality of cordless power tool batteries; and an auxiliary control circuit, capable of connecting to the main control circuit via wires to enable communication between the main control circuit and the auxiliary control circuit, the auxiliary control circuit being configured to, under the control of the main control circuit, direct the DC output power to recharge n≤m of the multiple cordless power tool batteries received by the multiple charging ports, respectively and continuously.

[0007] Some exemplary implementations provide a battery charger for charging multiple cordless power tool batteries, the battery charger comprising a housing and a charging circuit supported by or contained within the housing, the charging circuit comprising: a power circuit configured to convert alternating current (AC) input power into direct current (DC) output power; a plurality of electrical connectors connectable via wires to up to j>1 electrical loads comprising a plurality of docking stations, wherein each docking station comprises a separate housing configured to support or contain an auxiliary control circuit, and a plurality of charging ports configured to receive up to m>1 of a plurality of cordless power tool batteries; and a main control circuit configured to direct the DC output power to k≤j of the plurality of electrical connectors respectively and continuously connected to the k≤j electrical loads comprising the plurality of docking stations, and wherein, for each of the plurality of docking stations, the main control circuit is configured to control the auxiliary control circuit to direct the DC output power to respectively and continuously recharge n≤m of the plurality of cordless power tool batteries received by the plurality of charging ports.

[0008] Some exemplary implementations provide a docking station for charging multiple cordless power tool batteries, the docking station comprising: a housing; and auxiliary control circuitry supported by or contained within the housing; a plurality of charging ports configured to receive up to m>1 of the multiple cordless power tool batteries; and a charging circuit comprising: a power circuit configured to convert alternating current (AC) input power into direct current (DC) output power; a plurality of electrical connectors connectable via electrical wires to up to j>1 electrical loads including the docking station and including one or more expansion docking stations, wherein each docking station comprises a separate outer housing configured to support or contain a corresponding auxiliary control circuit; shell, and a corresponding plurality of charging ports configured to receive up to m>1 of a plurality of cordless power tool batteries; and a main control circuit configured to direct DC output power to k≤j of a plurality of electrical connectors respectively and continuously connected to k≤j electrical loads including a docking station and one or more expansion docking stations, and wherein, for each of the docking station and one or more expansion docking stations, the main control circuit is configured to control the auxiliary control circuit or the corresponding control circuit to direct the DC output power to recharge n≤m of a plurality of cordless power tool batteries received by the plurality of charging ports or the corresponding plurality of charging ports respectively and continuously.

[0009] By reading the following detailed description and the accompanying drawings briefly described below, these and other features, aspects and advantages of the present disclosure will become apparent. The present disclosure includes any combination of two, three, four or more features or elements set forth in the present disclosure, regardless of whether such features or elements are clearly combined or otherwise referenced in the specific exemplary implementations described herein. The present disclosure is intended to be read as a whole so that any separable features or elements of the present disclosure should be considered combinable in any aspect and exemplary implementation thereof, unless the context of the present disclosure clearly specifies otherwise.

[0010] Therefore, it will be understood that this brief overview is provided only to summarize some exemplary implementations in order to provide a basic understanding of some aspects of the present disclosure. Therefore, it will be understood that the above exemplary implementations are merely examples and should not be interpreted as narrowing the scope or spirit of the present disclosure in any way. Other exemplary implementations, aspects, and advantages will become apparent from the following detailed description in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of some of the described exemplary implementations. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Having generally described exemplary implementations of the present disclosure, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0012] Figure 1A system for charging a plurality of cordless power tool batteries according to some exemplary implementations of the present disclosure is shown;

[0013] Figure 2 A system according to some exemplary implementations is shown, which may correspond to Figure 1 The system shown in , and including a battery charger;

[0014] Figure 3 A system according to some exemplary implementations is shown, which may correspond to Figure 1 The system as shown in , and comprising a main docking station and one or more expansion docking stations; and

[0015] Figure 4 and Figure 5 is a flow chart illustrating various steps in a method of charging a plurality of cordless power tool batteries according to an exemplary implementation. DETAILED DESCRIPTION

[0016] Some implementations of the present disclosure will now be described more fully below with reference to the accompanying drawings, in which some but not all implementations of the present disclosure are shown. In fact, various implementations of the present disclosure may be implemented in many different forms and should not be construed as being limited to the implementations set forth herein; rather, these exemplary implementations are provided so that the present disclosure will be thorough and complete and will fully convey the scope of the present disclosure to those skilled in the art. The same reference numerals refer to the same elements throughout.

[0017] Unless otherwise stated or clear from the context, references to first, second, etc. should not be construed as implying a particular order. A feature described as being above another feature (unless otherwise stated or clear from the context) may be below the other feature, and vice versa; and similarly, a feature described as being to the left of another feature may instead be to the right, and vice versa. Furthermore, although reference may be made herein to quantitative measurements, values, geometric relationships, etc., unless otherwise stated, any one or more (if not all) of these may be absolute or approximate to take into account acceptable variations that may occur, such as variations due to engineering tolerances, etc.

[0018] As used herein, unless otherwise specified or clear from the context, an "or" of a set of operands is an "inclusive or," and thus is true only when one or more of the operands are true, whereas an "exclusive or" is false when all of the operands are true. Thus, for example, "[A] or [B]" is true if [A] is true, or if [B] is true, or if both [A] and [B] are true. In addition, the articles "a" and "an" mean "one or more," unless otherwise specified or the context clearly indicates the singular. Furthermore, it should be understood that the terms "data," "content," "digital content," and "information," and similar terms, are sometimes used interchangeably unless otherwise specified.

[0019] Exemplary implementations of the present disclosure relate generally to charging of rechargeable batteries, and specifically to charging cordless power tool batteries, such as 40 volt cordless power tool batteries used in many commercial lawn, garden, and landscaping operations. The system generally includes a charging circuit and a plurality of docking stations. The charging circuit may implement features of a sequential charging architecture having a single 500 watt or 750 watt charging circuit configured to charge multiple cordless power tool batteries in series one by one.

[0020] Each of the multiple docking stations can accommodate a subset of the multiple cordless power tool batteries. In a specific example, the system can include three docking stations, each docking station configured to accommodate up to four cordless power tool batteries, thereby providing a total charging capacity of twelve cordless power tool batteries. In various examples, the charging circuit can be provided by a separate battery charger; and in other examples, the charging circuit can be integrated with one of the multiple docking stations (the master docking station). In a suitable environment, the system can be set up in an enclosed workshop or building, where ten or more cordless power tool batteries can be recharged overnight and then transported to the job site via a conventional utility trailer.

[0021] According to an exemplary implementation of the present disclosure, ten or more cordless power tool batteries can then be charged through one charging circuit connected to an AC input power source (such as a mains power source). By using only one charger to charge multiple cordless power tool batteries one by one, the AC power usage required for charging can be reduced, and end users can better utilize their existing power infrastructure. This in turn can minimize the investment or modifications required to incorporate the system into their existing facilities. As an example, an ordinary U.S. household 110-volt wall socket can allow 1500 watts of power on a normal circuit, and each socket box can typically accept two (2) wall plugs. Therefore, the end user can easily plug two (2) 500-watt systems into an available wall socket, each system recharging ten or more cordless power tool batteries, and a total of twenty or more cordless power tool batteries can be recharged in one charging process. Therefore, the system can allow end users to easily and conveniently replenish a large number of cordless power tool batteries for daily use in one location of their facility.

[0022] Figure 1 A system 100 for charging multiple cordless power tool batteries 102 according to some exemplary implementations of the present disclosure is shown. As shown, the system includes a charging circuit 104 and a plurality of docking stations 106. As shown, the charging circuit includes a power circuit 108 configured to convert alternating current (AC) input power to direct current (DC) output power. In various more specific examples, the power circuit may include a power conversion and / or regulation circuit configured to receive AC mains power (from a mains power source) as AC input power and convert the AC mains power into regulated DC output power. The charging circuit also includes: a plurality of electrical connectors 110, which can be connected to up to j>1 electrical loads; and a main control circuit 112, which is configured to direct the DC output power to k≤j of the plurality of electrical connectors that are respectively and continuously connected to k≤j electrical loads.

[0023] In various examples, the charging circuit 104 may include a plurality of electrical connectors 110 to accommodate up to j docking stations, and the plurality of docking stations includes 1<k≤j docking stations. Figure 1 The system 100 shown in the figure includes three electrical connectors to accommodate up to three docking stations, but it should be understood that the system may include two electrical connectors to accommodate up to two docking stations; or include more than three electrical connectors to accommodate more than three docking stations (e.g., four docking stations, five docking stations, etc.).

[0024] Multiple docking stations 106 can be connected to multiple electrical connectors via wires 114 as k≤j electrical loads. Each of the multiple docking stations includes an electrical connector 116, multiple charging ports 118, and an auxiliary control circuit 120. The electrical connector can be connected to one of the multiple electrical connectors 110 via wires to receive DC output power from the charging circuit 104. The multiple charging ports are configured to receive up to m>1 of the multiple cordless power tool batteries 102. The auxiliary control circuit can be connected to the main control circuit via wires to enable communication between the main control circuit 112 and the auxiliary control circuit. In this regard, the auxiliary control circuit is configured to direct the DC output power to recharge n≤m of the multiple cordless power tool batteries received by the multiple charging ports separately and continuously under the control of the main control circuit.

[0025] In some examples, the auxiliary control circuit 120 includes an electronic switch 122 that can be controlled by the main control circuit 112 to switch the DC output power to recharge n≤m of the plurality of cordless power tool batteries separately and sequentially. Examples of suitable electronic switches include relays, transistors (e.g., MOSFETs), etc.

[0026] In some examples, each of the plurality of docking stations 106 also includes a plurality of voltage sensors 124 for the plurality of charging ports 118. In some of these examples, the plurality of voltage sensors are configured to determine a charge state of n≤m of the plurality of cordless power tool batteries 102.

[0027] In some examples, the main control circuit 112 is configured to communicate with the auxiliary control circuit 120 to identify the type and determine the charge state of n≤m of the plurality of cordless power tool batteries 102. In some of these examples, the main control circuit is configured to control the auxiliary control circuit to direct the DC output power based on the type and charge state of n≤m of the plurality of cordless power tool batteries.

[0028] In some examples, the main control circuit 112 is configured to control the DC output power to recharge each of the plurality of cordless power tool batteries 102 using at least one of a constant current (CC) charging profile or a constant voltage (CV) charging profile. In some additional examples, the main control circuit is configured to control the DC output power to recharge the plurality of cordless power tool batteries separately and continuously using a CC charging profile, and then separately and continuously using a CV charging profile. And in yet other examples, the main control circuit is configured to control the DC output power to recharge each of the plurality of cordless power tool batteries using a constant current, constant voltage (CCCV) charging profile.

[0029] In some examples, each of the plurality of docking stations 106 also includes a control panel 126 that is configured to individually or collectively display information regarding the charging status of n≤m of the plurality of cordless power tool batteries 102 .

[0030] In some examples, each docking station 106 includes a separate housing 128 configured to support or house the electrical connector 116, the plurality of charging ports 118, and the auxiliary control circuitry 120 of the docking station. The housing can be constructed in a variety of different ways and can be sufficiently rugged to withstand the vibration and shock of road transport; and the housing can be designed to accommodate n≤m of the plurality of cordless power tool batteries 102 during transport. In some additional examples, the separate housing of the docking station includes one or both of a carrying handle 130 or a wall mount. The carrying handle can improve the portability of the docking station, or the wall mount can be used to mount the docking station, such as to an inner wall of a utility trailer.

[0031] The charging circuit 104 can be supported or housed in a variety of different ways. As explained in more detail below, in some examples, the system also includes a battery charger that includes the charging circuit and includes an additional separate housing configured to support or house the charging circuit. In other examples, the plurality of docking stations 106 includes a main docking station and one or more expansion docking stations, and the separate housing of the main docking station is also configured to support or house the charging circuit.

[0032] Figure 2 A system 200 is shown, which in some examples may correspond to Figure 1 The system 100 shown in FIG. 1 and includes a battery charger 202. As indicated above, the battery charger includes a charging circuit 104 and an additional separate housing 204 configured to support or house the charging circuit. The system also includes a plurality of docking stations 106, which can be used in the same manner as described above with respect to Figure 1 The invention can be equipped and configured in the same or similar manner as described.

[0033] As also shown, in some examples, the battery charger 202 also includes an AC power plug 206 configured to connect the battery charger to an outlet 208 to provide AC input power from a mains power source. In some additional examples, the battery charger also includes a second charging circuit 104B that includes a second power circuit (similar to the power circuit 108). In some of these examples, the power circuit and the second power circuit are configured to receive AC input power in a parallel configuration.

[0034] refer to Figure 2 And further reference Figure 1In some examples, the plurality of electrical connectors 110 of the charging circuit 104 of the battery charger 202 can be connected to up to j>1 electrical loads (including the plurality of docking stations 106) via an external cable 210 including wires 114. Thus, the external cable can bundle wires through which the plurality of docking stations can be connected to the plurality of electrical connectors and through which the auxiliary control circuit 120 can be connected to the main control circuit 112. These external cables may or may not be detachable from the battery charger (e.g., quick connect). Likewise, the external cable may or may not be detachable from the plurality of docking stations.

[0035] In some examples, the housing 204 of the battery charger 202 includes one or both of a carrying handle or a wall mount bracket 212. Additionally or alternatively, in some examples, the battery charger also includes a control panel 214 that is configured to display information about the charging status of the plurality of cordless power tool batteries 102, either individually or collectively.

[0036] Figure 3 A system 300 is shown, which in some examples may correspond to Figure 1 The system 100 shown in FIG. 1 includes a main docking station 302 and one or more expansion docking stations 304. As described herein, the main docking station may sometimes be more simply referred to as a docking station relative to the one or more expansion docking stations. The one or more expansion docking stations may generally be similar to those described above with respect to Figure 1 The plurality of docking stations 106 described are equipped and configured in the same or similar manner.

[0037] refer to Figure 3 And further reference Figure 1 , the main docking station 302 may also be similarly equipped and configured as the docking station 106, but it may also be equipped with the charging circuit 104. In this regard, the main docking station may include a housing 306 (e.g., a separate housing 128) configured to support or house a plurality of charging ports 118 and auxiliary control circuits 120, as well as a charging circuit (including the power circuit 108, the plurality of electrical connectors 110, and the main control circuit 112) Figure 3 The main docking station may include an electrical connector 116 internally, which can be connected to one of the multiple electrical connectors of the charging circuit via a wire 114 to receive the DC output power from the charging circuit.

[0038] The main docking station 302 may be connectable to each of the expansion docking stations 304 via an external cable 308 including electrical wires 114. Thus, the external cable may bundle electrical wires by which the expansion docking station can be connected to one of the plurality of electrical connectors 110 of the charging circuit 104 and by which the auxiliary control circuitry 120 of the expansion docking station can be connected to the main control circuitry 112. As described above, the external cable may or may not be detachable from one or both of the expansion docking station or the main docking station.

[0039] Since the main docking station 302 is equipped with the charging circuit 104, in some examples, the main docking station includes an AC power plug 310, which is configured to connect the main docking station to a socket 312, and provide AC input power to the socket from the mains power supply. And as described above, in some other examples, the main docking station also includes a second charging circuit 104B, which includes a second power circuit (similar to the power circuit 108), and the power circuit and the second power circuit are configured to receive AC input power in a parallel configuration.

[0040] In some examples, the housing 306 of the master docking station 302 includes one or both of a carrying handle or a wall mount bracket 314. Additionally or alternatively, in some examples, the master docking station also includes a control panel 316 that is configured to display information about the charging status of multiple cordless power tool batteries 102, either individually or collectively. Additionally or alternatively, since the master docking station includes its own multiple charging ports 118, the control panel can be configured to display information about the charging status of n≤m of the multiple cordless power tool batteries 102 received by the multiple charging ports, either individually or collectively.

[0041] Go to again Figure 1 As indicated above, the control circuitry including each of the main control circuitry 112 and the auxiliary control circuitry 120 may include or communicate with various electronic components (including electronic switches, sensors, etc.). The control circuitry may also include a processing circuit, which is typically any computer hardware capable of processing information (e.g., data, computer programs, and / or other suitable electronic information). The processing circuitry is composed of a set of electronic circuits, some of which may be packaged as an integrated circuit or a plurality of interconnected integrated circuits (integrated circuits are sometimes more commonly referred to as "chips"). In other words, the processing circuitry may include one or more physical packages (e.g., chips), including materials, components, and / or wires on a structural assembly (e.g., a substrate). The structural assembly may provide physical strength, conservation of size, and / or limitations of electrical interactions for the component circuits included thereon. Therefore, in some cases, the processing circuitry may be configured to implement aspects of the present disclosure on a single chip or as a single "system on a chip."

[0042] The processing circuit may be composed of one or more processors alone, or in combination with one or more computer-readable storage media. One or more processors may be implemented as or otherwise include various processing devices, such as one or more of a microprocessor, a coprocessor, a controller, or other computing or processing devices, including integrated circuits, such as ASICs (application-specific integrated circuits), FPGAs (field programmable gate arrays), etc. In an exemplary implementation, one or more processors may be configured to execute instructions stored in one or more computer-readable storage media. In this regard, a computer-readable storage medium is generally any computer hardware capable of temporarily and / or permanently storing information (e.g., data, computer programs (e.g., computer-readable program codes), and / or other suitable information). A computer-readable storage medium may include volatile and / or non-volatile memory, and may be fixed or removable. A computer-readable storage medium is a non-temporary device capable of storing information, and is different from a computer-readable transmission medium (such as an electronic temporary signal capable of carrying information from one location to another).

[0043] Figure 4 4 is a flow chart illustrating various steps in a method 400 for charging a plurality of cordless power tool batteries 102 using a system 200 including a battery charger 202 and a plurality of docking stations 106 according to various exemplary implementations. The method includes connecting an AC power plug 206 of a battery charger to an outlet 208 to which AC input power is provided from a mains power source, the battery charger including a charging circuit 104 that converts the AC input power to a DC output power, as shown at block 402. The method includes connecting the battery charger to a plurality of docking stations, as shown at block 404. The method includes receiving a plurality of cordless power tool batteries in a plurality of docking stations, wherein each docking station includes a plurality of charging ports 118 that receive n≤m of the plurality of cordless power tool batteries, as shown at block 406. The method includes directing the DC output power from the battery charger to the plurality of docking stations, respectively and successively, as shown at block 408. And when the DC output power is directed to each docking station, the method includes directing the DC output power to respectively and sequentially recharge n≤m of a plurality of cordless power tool batteries received by the plurality of charging ports, as shown at block 410 .

[0044] Figure 5is a flow chart showing various steps in a method 500 for charging a plurality of cordless power tool batteries 102 using a system 300 including a main docking station 302 and one or more expansion docking stations 304 according to various exemplary implementations. The method includes: connecting an AC power plug 310 of a main docking station to an outlet 312, providing AC input power to the outlet from a mains power source, and the main docking station converting the AC input power to DC output power, as shown at block 502. The method includes: connecting the main docking station to one or more expansion docking stations, as shown at block 504. The method includes: receiving a plurality of cordless power tool batteries in the main docking station and the one or more expansion docking stations, wherein each docking station includes a plurality of charging ports 118 for receiving n≤m of the plurality of cordless power tool batteries, as shown at block 506. The method includes: directing the DC output power from the main docking station to the main docking station and the one or more expansion docking stations, respectively and successively, as shown at block 508. And when the DC output power is directed to each docking station, the method includes directing the DC output power to respectively and sequentially recharge n≤m of a plurality of cordless power tool batteries received by the plurality of charging ports, as shown at block 510 .

[0045] As explained above and repeated below, the present disclosure includes, but is not limited to, the following exemplary implementations.

[0046] Item 1. A system for charging multiple cordless power tool batteries, the system comprising: a charging circuit, including: a power circuit configured to convert alternating current (AC) input power into direct current (DC) output power; a plurality of electrical connectors capable of connecting to up to j>1 electrical loads; and a main control circuit configured to direct the DC output power to k≤j of the plurality of electrical connectors that are respectively and continuously connected to k≤j electrical loads; and a plurality of docking stations capable of connecting to the plurality of electrical connectors via wires as k≤j electrical loads, each of the plurality of docking stations comprising: an electrical connector capable of connecting to one of the plurality of electrical connectors via wires to receive the DC output power from the charging circuit; a plurality of charging ports configured to receive up to m>1 of a plurality of cordless power tool batteries; and an auxiliary control circuit capable of connecting to the main control circuit via wires to enable communication between the main control circuit and the auxiliary control circuit, the auxiliary control circuit being configured to, under the control of the main control circuit, direct the DC output power to respectively and continuously recharge n≤m of the plurality of cordless power tool batteries received by the plurality of charging ports.

[0047] Clause 2. The system of clause 1, wherein the auxiliary control circuit comprises an electronic switch controllable by the main control circuit to switch the DC output power to individually and sequentially recharge n≤m of the plurality of cordless power tool batteries.

[0048] Clause 3. A system according to clause 1 or clause 2, wherein each of the plurality of docking stations further comprises a plurality of voltage sensors for the plurality of charging ports, the plurality of voltage sensors being configured to determine a charging state of n≤m of the plurality of cordless power tool batteries.

[0049] Clause 4. A system according to any of clauses 1 to 3, wherein the main control circuit is configured to communicate with the auxiliary control circuit to identify the type of n≤m of a plurality of cordless power tool batteries and determine their charging status, and wherein the main control circuit is configured to control the auxiliary control circuit to direct DC output power based on the type and charging status of n≤m of the plurality of cordless power tool batteries.

[0050] Clause 5. A system according to any of clauses 1 to 4, wherein the main control circuit is configured to control the DC output power to recharge each of a plurality of cordless power tool batteries using at least one of a constant current (CC) charging curve or a constant voltage (CV) charging curve.

[0051] Clause 6. The system of clause 5, wherein the main control circuit is configured to control the DC output power to recharge the plurality of cordless power tool batteries individually and continuously using a CC charging curve, and then individually and continuously using a CV charging curve.

[0052] Clause 7. The system of any of clauses 1 to 6, wherein the main control circuit is configured to control the DC output power to recharge each of the plurality of cordless power tool batteries using a constant current, constant voltage (CCCV) charging profile.

[0053] Clause 8. The system of any of Clauses 1 to 7, wherein each of the plurality of docking stations further comprises a control panel configured to individually or collectively display information regarding a charging status of n≤m of the plurality of cordless power tool batteries.

[0054] Clause 9. The system of any of clauses 1 to 8, wherein each docking station comprises a separate housing configured to support or house an electrical connector, a plurality of charging ports, and auxiliary control circuitry of the docking station.

[0055] Clause 10. The system of clause 9, wherein the separate housing of the docking station includes one or both of a carrying handle or a wall mount bracket.

[0056] Clause 11. The system of clause 9 or clause 10, wherein the system further comprises a battery charger comprising a charging circuit and comprising an additional separate housing configured to support or house the charging circuit.

[0057] Clause 12. The system of clause 11, wherein the additional separate housing of the battery charger comprises one or both of a carrying handle or a wall mount bracket.

[0058] Clause 13. The system of clause 11 or clause 12, wherein the plurality of docking stations are connectable to the plurality of electrical connectors of the battery charger via an external cable comprising electrical wires.

[0059] Clause 14. The system of clause 13, wherein the external cable is detachable from one or both of the plurality of docking stations or the battery charger.

[0060] Clause 15. The system of clause 13 or clause 14, wherein the external cable is not detachable from one or both of the plurality of docking stations or the battery charger.

[0061] Clause 16. The system of any of Clauses 11 to 15, wherein the battery charger further comprises a control panel configured to display information regarding the charging status of the plurality of cordless power tool batteries, either individually or collectively.

[0062] Clause 17. The system of any of Clauses 11 to 16, wherein the battery charger further comprises an AC power plug configured to connect the battery charger to an outlet to which AC input power is provided from a mains power source.

[0063] Clause 18. The system of any of clauses 11 to 17, wherein the battery charger further comprises a second charging circuit comprising a second power circuit, and wherein the power circuit and the second power circuit are configured to receive AC input power in a parallel configuration.

[0064] Clause 19. The system of any of clauses 9 to 18, wherein the plurality of docking stations includes a master docking station and one or more expansion docking stations, and the separate housing of the master docking station is further configured to support or house a charging circuit.

[0065] Clause 20. A system according to clause 19, wherein the master docking station is connectable to each expansion docking station via an external cable, the external cable comprising electrical wires, via which the expansion docking station is connectable to one of the plurality of electrical connectors of the charging circuit and thereby to the master docking station.

[0066] Clause 21. The system of clause 20, wherein the external cable is detachable from one or both of the expansion docking station or the main docking station.

[0067] Clause 22. The system of any of Clauses 19 to 21, wherein the master docking station further comprises a control panel configured to display information regarding the charging status of the plurality of cordless power tool batteries, either individually or collectively.

[0068] Clause 23. The system of any of clauses 19 to 22, wherein the master docking station further comprises an AC power plug configured to connect the master docking station to an outlet to which AC input power is provided from a mains power source.

[0069] Clause 24. The system of any of clauses 19 to 23, wherein the master docking station further comprises a second charging circuit comprising a second power circuit, and wherein the power circuit and the second power circuit are configured to receive AC input power in a parallel configuration.

[0070] Item 25. A battery charger for charging multiple cordless power tool batteries, the battery charger comprising a housing and a charging circuit supported by or contained within the housing, the charging circuit comprising: a power circuit configured to convert alternating current (AC) input power to direct current (DC) output power; a plurality of electrical connectors connectable via wires to up to j>1 electrical loads comprising a plurality of docking stations, wherein each docking station comprises a separate housing configured to support or contain an auxiliary control circuit, and a plurality of charging ports configured to receive up to m>1 of a plurality of cordless power tool batteries; and a main control circuit configured to direct the DC output power to k≤j of the plurality of electrical connectors respectively and continuously connected to the k≤j electrical loads comprising the plurality of docking stations, and wherein, for each of the plurality of docking stations, the main control circuit is configured to control the auxiliary control circuit to direct the DC output power to respectively and continuously recharge n≤m of the plurality of cordless power tool batteries received by the plurality of charging ports.

[0071] Item 26. A battery charger according to Item 25, wherein the main control circuit is configured to communicate with the auxiliary control circuit to identify the type of n≤m of the multiple cordless power tool batteries and determine their charging status, and wherein the main control circuit is configured to control the auxiliary control circuit to direct the DC output power based on the type and charging status of n≤m of the multiple cordless power tool batteries.

[0072] Clause 27. A battery charger according to clause 25 or clause 26, wherein the main control circuit is configured to control the DC output power to recharge each of the plurality of cordless power tool batteries using at least one of a constant current (CC) charging profile or a constant voltage (CV) charging profile.

[0073] Clause 28. The battery charger of Clause 27, wherein the main control circuit is configured to control the DC output power to recharge the plurality of cordless power tool batteries separately and continuously using a CC charging curve and then separately and continuously using a CV charging curve.

[0074] Clause 29. The battery charger of any of clauses 25 to 28, wherein the main control circuit is configured to control the DC output power to recharge each of the plurality of cordless power tool batteries using a constant current, constant voltage (CCCV) charging profile.

[0075] Clause 30. The battery charger of any of Clauses 25 to 29, wherein the housing of the battery charger includes one or both of a carrying handle or a wall mount bracket.

[0076] Clause 31. The battery charger of any of clauses 25 to 30, wherein the plurality of electrical connectors are connectable to up to j>1 docking stations via an external cable including electrical wires.

[0077] Clause 32. The battery charger of clause 31, wherein the external cable is detachable from the battery charger.

[0078] Clause 33. A battery charger according to clause 31 or clause 32, wherein the external cable is not detachable from the battery charger.

[0079] Clause 34. The battery charger of any one of Clauses 25 to 33, wherein the battery charger further comprises a control panel configured to display information regarding the charging status of the plurality of cordless power tool batteries, either individually or collectively.

[0080] Clause 35. The battery charger of any one of clauses 25 to 34, wherein the battery charger further comprises an AC power plug configured to connect the battery charger to an outlet to provide AC input power from a mains power source.

[0081] Clause 36. The battery charger of any of clauses 25 to 35, wherein the battery charger further comprises a second charging circuit comprising a second power circuit, and wherein the power circuit and the second power circuit are configured to receive AC input power in a parallel configuration.

[0082] Clause 37. A docking station for charging a plurality of cordless power tool batteries, the docking station comprising: a housing; and auxiliary control circuitry supported by or contained within the housing; a plurality of charging ports configured to receive up to m>1 of the plurality of cordless power tool batteries; and a charging circuit comprising: a power circuit configured to convert alternating current (AC) input power to direct current (DC) output power; a plurality of electrical connectors connectable via electrical wires to up to j>1 electrical loads including the docking station and including one or more expansion docking stations, wherein each docking station comprises a separate housing configured to support or contain a corresponding auxiliary control circuit, so as to and a corresponding plurality of charging ports configured to receive up to m>1 of a plurality of cordless power tool batteries; and a main control circuit configured to direct DC output power to k≤j of a plurality of electrical connectors respectively and continuously connected to k≤j electrical loads including a docking station and one or more expansion docking stations, and wherein, for each of the docking station and one or more expansion docking stations, the main control circuit is configured to control the auxiliary control circuit or the corresponding control circuit to direct the DC output power to recharge n≤m of a plurality of cordless power tool batteries received by the plurality of charging ports or the corresponding plurality of charging ports respectively and continuously.

[0083] Clause 38. The docking station of clause 37, wherein the auxiliary control circuit comprises an electronic switch controllable by the main control circuit to switch the DC output power to individually and sequentially recharge n≤m of the plurality of cordless power tool batteries.

[0084] Clause 39. A docking station according to clause 37 or clause 38, wherein the docking station further comprises a plurality of voltage sensors for the plurality of charging ports, the plurality of voltage sensors being configured to determine a charging state of n≤m of the plurality of cordless power tool batteries.

[0085] Clause 40. A docking station according to any one of clauses 37 to 39, wherein the main control circuit is configured to communicate with the auxiliary control circuit to identify the type of n≤m of a plurality of cordless power tool batteries and determine their charging status, and wherein the main control circuit is configured to control the auxiliary control circuit to direct DC output power based on the type and charging status of n≤m of the plurality of cordless power tool batteries.

[0086] Clause 41. A docking station according to any of clauses 37 to 40, wherein the main control circuit is configured to control the DC output power to recharge each of a plurality of cordless power tool batteries using at least one of a constant current (CC) charging curve or a constant voltage (CV) charging curve.

[0087] Clause 42. The docking station of clause 41, wherein the main control circuit is configured to control the DC output power to recharge the plurality of cordless power tool batteries individually and continuously using a CC charging curve, and then individually and continuously using a CV charging curve.

[0088] Clause 43. The docking station of any of clauses 37 to 42, wherein the main control circuit is configured to control the DC output power to recharge each of the plurality of cordless power tool batteries using a constant current, constant voltage (CCCV) charging profile.

[0089] Clause 44. The docking station of clause 43, wherein the housing comprises one or both of a carrying handle or a wall mount bracket.

[0090] Clause 45. A docking station according to any one of clauses 37 to 44, wherein the main docking station is connectable to each expansion docking station via an external cable, the external cable comprising electrical wires, via which the expansion docking station is connectable to one of a plurality of electrical connectors of the charging circuit and thereby to the docking station.

[0091] Clause 46. The docking station of clause 45, wherein the external cable is detachable from one or both of the expansion dock or the docking station.

[0092] Clause 47. The docking station of any of clauses 37 to 46, wherein the docking station further comprises a control panel configured to display information regarding the charging status of the plurality of cordless power tool batteries, either individually or collectively.

[0093] Clause 48. The docking station of any of Clauses 37 to 47, wherein the docking station further comprises a control panel configured to display information regarding the charging status of n≤m of the plurality of cordless power tool batteries, either individually or collectively.

[0094] Clause 49. The docking station of any of clauses 37 to 48, wherein the docking station further comprises an AC power plug configured to connect the docking station to an outlet to provide AC input power from a mains power source to the outlet.

[0095] Clause 50. The docking station of any of clauses 37 to 49, wherein the docking station further comprises a second charging circuit comprising a second power circuit, and wherein the power circuit and the second power circuit are configured to receive AC input power in a parallel configuration.

[0096] Item 51. A method for charging multiple cordless power tool batteries using a system including a battery charger and multiple docking stations, the method comprising: connecting an AC power plug of the battery charger to a socket, providing AC input power from a mains power source to the socket, the battery charger including a charging circuit that converts the AC input power into DC output power; connecting the battery charger to multiple docking stations; receiving multiple cordless power tool batteries in the multiple docking stations, wherein each docking station includes multiple charging ports that receive n≤m of the multiple cordless power tool batteries; separately and continuously directing the DC output power from the battery charger to the multiple docking stations; and when the DC output power is directed to each docking station, directing the DC output power to separately and continuously recharge n≤m of the multiple cordless power tool batteries received by the multiple charging ports.

[0097] Item 52. A method for charging multiple cordless power tool batteries using a system including a main docking station and one or more expansion docking stations, the method comprising: connecting the AC power plug of the main docking station to a socket, providing AC input power from a mains power source to the socket, the main docking station converting the AC input power into DC output power; connecting the main docking station to one or more expansion docking stations; receiving multiple cordless power tool batteries in the main docking station and the one or more expansion docking stations, wherein each docking station includes multiple charging ports for receiving n≤m of the multiple cordless power tool batteries; separately and continuously directing the DC output power from the main docking station to the main docking station and the one or more expansion docking stations; and when the DC output power is directed to each docking station, directing the DC output power to separately and continuously recharge n≤m of the multiple cordless power tool batteries received by the multiple charging ports.

[0098] Benefiting from the teachings presented in the foregoing description and the related drawings, those skilled in the art to which the present disclosure belongs will think of many modifications and other implementations of the present disclosure set forth herein. Therefore, it should be understood that the present disclosure is not limited to the specific implementations disclosed, and modifications and other implementations are intended to be included within the scope of the appended claims. In addition, although the foregoing description and the related drawings describe exemplary implementations in the context of certain exemplary combinations of elements and / or functions, it should be understood that different combinations of elements and / or functions may be provided by alternative implementations without departing from the scope of the appended claims. In this regard, for example, as some of the appended claims may set forth, it is also possible to envision a combination of elements and / or functions that are different from the above-mentioned explicit descriptions. Although specific terms are employed herein, they are used only in a general and descriptive sense, and not for the purpose of limitation.

Claims

1. A system for charging a plurality of cordless power tool batteries, the system comprising: Charging circuit, comprising: A power circuit configured to convert alternating current (AC) input power into direct current (DC) output power; a plurality of electrical connectors capable of connecting to up to j>1 electrical loads; and a main control circuit configured to direct the DC output power to k≤j of the plurality of electrical connectors respectively and successively connected to k≤j electrical loads; and A plurality of docking stations, which can be connected to the plurality of electrical connectors via electrical wires as the k≤j electrical loads, each of the plurality of docking stations comprising: an electrical connector connectable to one of the plurality of electrical connectors via the electrical wire to receive the DC output power from the charging circuit; a plurality of charging ports configured to receive up to m>1 of the plurality of cordless power tool batteries; and An auxiliary control circuit can be connected to the main control circuit through the electric wire to realize communication between the main control circuit and the auxiliary control circuit. The auxiliary control circuit is configured to guide the DC output power to recharge n≤m of the multiple cordless power tool batteries received by the multiple charging ports separately and continuously under the control of the main control circuit.

2. The system according to claim 1, wherein: The main control circuit is configured to communicate with the auxiliary control circuit to identify the type of the n≤m of the plurality of cordless power tool batteries and determine the charge status of the n≤m of the plurality of cordless power tool batteries, and Wherein, the main control circuit is configured to control the auxiliary control circuit to direct the DC output power based on the type and charging status of the n≤m of the plurality of cordless power tool batteries.

3. The system according to claim 1, wherein: The main control circuit is configured to control the DC output power to recharge the plurality of cordless power tool batteries individually and continuously using a constant current CC charging curve, and then individually and continuously recharge using a constant voltage CV charging curve.

4. The system according to claim 1, wherein: Each docking station includes a separate housing configured to support or house the electrical connector, the plurality of charging ports, and the auxiliary control circuitry of the docking station.

5. The system according to claim 4, wherein: The system also includes a battery charger including the charging circuit and including an additional separate housing configured to support or house the charging circuit.

6. The system according to claim 5, wherein: The plurality of docking stations are connectable to the plurality of electrical connectors of the battery charger via an external cable including the electrical wires.

7. The system according to claim 5, wherein: The battery charger also includes a control panel configured to display information regarding the charging status of the plurality of cordless power tool batteries, either individually or collectively.

8. The system according to claim 5, wherein: The battery charger also includes a second charging circuit including a second power circuit, and Wherein, the power circuit and the second power circuit are configured to receive the AC input power in a parallel configuration.

9. The system according to claim 5, wherein: The plurality of docking stations include a main docking station and one or more expansion docking stations, and the separate housing of the main docking station is further configured to support or house the charging circuit.

10. The system according to claim 5, wherein: The master docking station is connectable to each of the expansion docking stations by an external cable including the electrical wires, and the expansion docking stations are connectable to one of the plurality of electrical connectors of the charging circuit and thereby to the master docking station by the electrical wires.

11. The system according to claim 5, wherein: The master docking station also includes a control panel configured to display information regarding the charging status of the plurality of cordless power tool batteries, either individually or collectively.

12. The system according to claim 5, wherein: The master docking station also includes a second charging circuit, the second charging circuit includes a second power circuit, and Wherein, the power circuit and the second power circuit are configured to receive the AC input power in a parallel configuration.

13. A battery charger for charging a plurality of cordless power tool batteries, the battery charger comprising a housing and a charging circuit supported by or contained within the housing, the charging circuit comprising: A power circuit configured to convert alternating current (AC) input power into direct current (DC) output power; a plurality of electrical connectors capable of being connected by electrical wires to up to j>1 electrical loads including a plurality of docking stations, each docking station including a separate housing configured to support or house auxiliary control circuitry, and a plurality of charging ports configured to receive up to m>1 of the plurality of cordless power tool batteries; as well as a main control circuit configured to direct the DC output power to k≤j of the plurality of electrical connectors respectively and successively connected to k≤j electrical loads comprising the plurality of docking stations, and Wherein, for each of the plurality of docking stations, the main control circuit is configured to control the auxiliary control circuit to direct the DC output power to recharge n≤m of the plurality of cordless power tool batteries received by the plurality of charging ports respectively and continuously.

14. The battery charger according to claim 13, wherein: The main control circuit is configured to communicate with the auxiliary control circuit to identify the type of the n≤m of the plurality of cordless power tool batteries and determine the charge status of the n≤m of the plurality of cordless power tool batteries, and Wherein, the main control circuit is configured to control the auxiliary control circuit to direct the DC output power based on the type and charging status of the n≤m of the plurality of cordless power tool batteries.

15. The battery charger according to claim 13, wherein: The main control circuit is configured to control the DC output power to recharge the plurality of cordless power tool batteries individually and continuously using a constant current CC charging curve, and then individually and continuously recharge using a constant voltage CV charging curve.

16. The battery charger according to claim 13, wherein: The battery charger also includes a control panel configured to display information regarding the charging status of the plurality of cordless power tool batteries, either individually or collectively.

17. The battery charger according to claim 13, wherein: The battery charger also includes a second charging circuit including a second power circuit, and Wherein, the power circuit and the second power circuit are configured to receive the AC input power in a parallel configuration.

18. A docking station for charging a plurality of cordless power tool batteries, the docking station comprising: shell; and supported by or contained in the housing, Auxiliary control circuit; a plurality of charging ports configured to receive up to m>1 of the plurality of cordless power tool batteries; as well as Charging circuit, comprising: A power circuit configured to convert alternating current (AC) input power into direct current (DC) output power; a plurality of electrical connectors connectable by electrical wires to up to j>1 electrical loads including the docking station and including one or more expansion docking stations, each docking station including a separate housing configured to support or house a respective auxiliary control circuit and a respective plurality of charging ports configured to receive up to m>1 of the plurality of cordless power tool batteries; and a main control circuit configured to direct the DC output power to k≤j of the plurality of electrical connectors respectively and successively connected to k≤j electrical loads including the docking station and one or more expansion docking stations, and Wherein, for the docking station and each of the one or more expansion docking stations, the main control circuit is configured to control the auxiliary control circuit or the corresponding control circuit to guide the DC output power to recharge n≤m of the multiple cordless power tool batteries received by the multiple charging ports or the corresponding multiple charging ports respectively and continuously.

19. The docking station of claim 18, wherein: The main control circuit is configured to communicate with the auxiliary control circuit to identify the type of the n≤m of the plurality of cordless power tool batteries and determine the charge status of the n≤m of the plurality of cordless power tool batteries, and Wherein, the main control circuit is configured to control the auxiliary control circuit to direct the DC output power based on the type and charging status of the n≤m of the plurality of cordless power tool batteries.

20. The docking station of claim 18, wherein: The main control circuit is configured to control the DC output power to recharge the plurality of cordless power tool batteries individually and continuously using a constant current CC charging curve, and then individually and continuously recharge using a constant voltage CV charging curve.

21. The docking station of claim 18, wherein: The docking station also includes a control panel configured to display information regarding the charging status of the plurality of cordless power tool batteries, either individually or collectively.

22. The docking station of claim 18, wherein: The docking station also includes a second charging circuit, the second charging circuit includes a second power circuit, and Wherein, the power circuit and the second power circuit are configured to receive the AC input power in a parallel configuration.

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